11A-0-1
ENGINE
6G7 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-5
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-6
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
3. ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
4. AIR INTAKE PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5-1
6. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
7. INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. EXHAUST MANIFOLD & WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
9. ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1
13. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . . 11A-13-1
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-0-3
6G7 ENGINE (E-W) - General Information
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions
6G72-SOHC
Type
60_ OHV, SOHC
Number of cylinders
Combustion chamber
Total displacement dm3
Cylinder bore mm
Piston stroke mm
6
Compact type
2.972
91.1
76.0
Compression ratio
8.9
Valve timing
(Camshaft identifica-
tion mark: 1)
Intake valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
15°
53°
Exhaust valve
53°
15°
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Trochoid type
Cooling system
Water pump type
Water-cooled forced circulation
Centrifugal impeller type
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-1-1
6G7 ENGINE (E-W) - Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items
Standard
Limit
Timing belt
Auto-tensioner rod length mm
Auto-tensioner rod projection length mm
3.8 - 5.0
12
-
-
-
Auto-tensioner rod pushed-in amount (when pushed with a force of 98 1.0 or less
- 196 N) mm
Rocker arms and camshaft
Camshaft cam height mm (Identification
mark: 1)
Intake
37.71
37.14
45
37.21
Exhaust
36.64
Camshaft journal outside diameter mm
-
-
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
4 - 20/1.0
Cylinder head and valves
Cylinder head flatness of gasket surface mm
Less than 0.03
-
0.2
0.2
Cylinder head grinding limit of gasket surface mm
(Total resurfacing depth of both cylinder head and cylinder block)
Cylinder head overall height mm
120
-
Valve thickness of valve head (margin) mm
Intake
1.0
0.5
Exhaust
Intake
1.2
0.7
Valve overall height mm
112.30
114.11
6.0
111.80
Exhaust
Intake
113.61
Valve stem outside diameter mm
Valve thickness to valve guide clearance mm
-
Exhaust
Intake
6.0
-
0.02 - 0.04
0.04 - 0.06
45_ - 45.5_
51.0
0.10
0.15
-
Exhaust
Valve face angle mm
Valve spring free length mm
50.0
-
Valve spring load/installed height N/mm
Valve spring out-of-squareness
Valve seat valve contact width mm
Valve guide inside diameter mm
267/44.2
2_ or less
0.9 - 1.3
6.0
Maximum 4_
-
-
Valve guide projection from cylinder head upper surface mm
Valve stem projection mm
14
-
49.3
49.8
Oil pan and oil pump
Oil pump tip clearance mm
0.06 - 0.18
-
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-1-2
6G7 ENGINE (E-W) - Specifications
Items
Standard
Limit
-
Oil pump side clearance mm
Oil pump body clearance mm
Piston and connecting rod
Piston outside diameter mm
0.04 -0.10
0.10 - 0.18
0.35
91.1
-
Piston ring to ring groove clearance mm
No. 1
0.03 - 0.07
0.02 - 0.06
0.30 - 0.45
0.45 - 0.60
0.20 - 0.60
22.0
0.1
0.1
0.8
0.8
1.0
-
No. 2
Piston ring end gap mm
No. 1
No. 2
Oil ring side rail
Piston pin outside diameter mm
Piston pin press-in load N (Room temperature)
Crankshaft pin oil clearance mm
7,350 - 17,200
0.02 - 0.05
0.10 - 0.25
-
0.1
0.4
Connecting rod big end side clearance mm
Crankshaft, flywheel and drive plate
Crankshaft end play mm
0.05 - 0.25
0.3
-
Crankshaft journal outside diameter mm
Crankshaft pin outside diameter mm
Crankshaft journal oil clearance mm
Piston to cylinder clearance mm
60
50
-
0.02 - 0.05
0.1
-
0.02 - 0.04
Cylinder block flatness of gasket surface mm
0.05
-
0.1
0.2
Cylinder block grinding limit of gasket surface mm
(Total resurfacing depth of both cylinder head and cylinder block)
Cylinder block overall height mm
Cylinder bore inside diameter mm
Cylindricity mm
210.5
91.1
0.01
-
-
-
REWORK DIMENSIONS
Items
Standard value
11.05 - 11.07
11.25 - 11.27
11.50 - 11.52
34.30 - 34.33
34.60 - 34.63
31.80 - 31.83
32.10 - 32.13
Limit
Oversize rework dimensions of valve
guide hole mm
0.05 Oversize diameter
0.25 Oversize diameter
0.50 Oversize diameter
0.3 Oversize diameter
0.6 Oversize diameter
0.3 Oversize diameter
0.6 Oversize diameter
-
-
-
-
-
-
-
Oversize rework dimensions of intake
valve seat hole mm
Oversize rework dimensions of
exhaust valve seat hole mm
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-1-3
6G7 ENGINE (E-W) - Specifications
TORQUE SPECIFICATIONS
Items
Nm
Alternator
Drive belt tensioner pulley nut
Crankshaft bolt
49
181
44
21
48
13
Alternator pivot nut
Alternator bolt M8
Alternator bolt M10
Dipstick tube
Air intake plenum
Air intake plenum stay bolt M8
Air intake plenum stay bolt M10
Accelerator cable bracket
Bracket
17
35
4
11
11
17
21
17
56
Throttle body bolt
Air intake plenum bolt and nut
Exhaust gas recirculation valve bolt
Exhaust gas recirculation pipe bolt
Exhaust gas recirculation pipe flare nut
Ignition system
Spark plugs
25
23
Distributor
Timing belt
Timing belt cover bolt M6
Timing belt cover bolt M8
Engine support bracket
Crankshaft angle sensor bolt
Auto tensioner bolt
Tensioner pulley bolt
Tensioner arm bolt
11
13
44
9
23
48
44
44
88
23
13
Idler pulley bolt
Camshaft sprocket bolt
Bracket
Timing belt rear cover bolt
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-1-4
6G7 ENGINE (E-W) - Specifications
Items
Nm
Intake manifold
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Heater pipe bolt
11
29
18
18
18
18
13
11
Water outlet fitting bolt
Water inlet fitting bolt
Thermostat housing bolt
Water pipe bolt
Delivery pipe
Intake manifold bolt
Fuel pipe bolt
21
8.8
8.8
Fuel pressure regulator bolt
Exhaust manifold
Heat protector bolt
13
49
35
13
23
41
Exhaust manifold bolt
Engine hanger
Oil level gauge guide bolt
Water pump bolt M8
Water pump bolt M10
Rocker arms and camshaft
Rocker cover bolt
3.4
31
12
Rocker shaft bolt
Thrust case bolt
Cylinder head and valve
Cylinder head bolt
108
Oil pan and oil pump
Oil pressure switch
Oil filter bracket bolt M8
Oil filter bracket bolt M10
Drain plug
9.8
23
41
39
11
11
Oil pan, lower bolt
Cover bolt
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-1-5
6G7 ENGINE (E-W) - Specifications
Items
Nm
5.9
11
Oil pan, upper bolt
Baffle plate bolt (oil pan side)
Baffle plate bolt (cylinder block side)
Oil screen bolt
9.8
18
Relief plug
44
Oil pump case bolt
Oil pump cover bolt
Piston and connecting rod
Connecting rod cap
Crankshaft, flywheel and drive plate
Flywheel bolt
13
9.8
51
74
74
11
11
93
Drive plate bolt
Rear plate bolt
Oil seal case bolt
Bearing cap bolt
SEALANTS
Description
Specified sealant
Quantity
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Oil pressure switch
Oil pan
3M ATD Part No. 8660
3M Nut Locking Part No. 4171
3M ATD Part No. 8660
As required
As required
As required
MITSUBISHI GENUINE Part No. MD970389 As required
MITSUBISHI GENUINE Part No. MD970389 As required
MITSUBISHI GENUINE Part No. MD970389 As required
Oil pump case
Oil seal case
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-1-6
6G7 ENGINE (E-W) - Specifications
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine
oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
Form-in-Place Gasket Application (FIPG)
When assembling parts with the FIPG, you must observe some precautions, but the procedure is very
simple as in the case of a conventional pre-cut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-2-1
6G7 ENGINE (E-W) - Special Tools
2. SPECIAL TOOLS
Tool
Number
Name
Use
MB991559
MD998051
MD998440
MD998441
MD998442
MD998443
MD998717
MD998718
MD998772
Camshaft oil seal Installation of camshaft oil seal (on left bank)
installer adaptor (Used in combination with MD998713)
Cylinder head bolt Loosening and tightening of cylinder head bolt
wrench
Leak-down tester
Lash adjuster
Air bleed wire
Leak-down test of lash adjuster
Air bleeding of lash adjuster retainer
Air bleeding of lash adjuster
Auto-lash adjuster Holding of the lash adjuster to prevent it from
holder
falling when rocker shaft assembly is removed
or installed
Crankshaft front oil Installation of crankshaft front oil seal installer
seal
Crankshaft rear oil Press fitting crankshaft rear oil
seal installer
Valve spring
compressor
Compressing of the valve springs
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-2-2
6G7 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998774
Valve stem seal Installation of valve stem seal
installer
MD998780
MD998781
MD998767
MB990767
MD998715
MD998735
MD998769
MD998713
Piston pin setting Removal and installation of piston pin
tool
Flywheel stopper
Tensioner pulley
End yoke holder
Pulley holder pin
Holding flywheel or drive plate
Adjustment of timing belt tension
Holding camshaft sprocket
(Used in combination with MD998715)
Holding camshaft sprocket
(Used in combination with MB990767)
Valve spring
compressor
adaptor
Compressing the valve springs
Crank pulley
spacer
Cranking the crankshaft to install timing belt
Camshaft oil seal Installation of camshaft oil seal
installer
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-3-1
6G7 ENGINE (E-W) - Alternator
3. ALTERNATOR
REMOVAL AND INSTALLATION
7
8
9
181 Nm
13 Nm
10
21 Nm
2
48 Nm
44 Nm
6
1
49 Nm
3
4
5
7EN1030
Removal steps
1. Tensioner pulley
6. Alternator bracket
7. Dip stick
AA" "AA 2. Crankshaft bolt
3. Washer
8. O-ring
4. Crankshaft pulley
5. Alternator
9. Dip stick tube
10. O-ring
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-3-2
6G7 ENGINE (E-W) - Alternator
REMOVAL SERVICE POINTS
AA" CRANKSHAFT BOLT
MD998781
(1) With the Special Tool fixed to the drive plate or flywheel
remove the crankshaft bolt.
7EN0856
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT BOLT
(1) With the Special Tool fixed to the drive plate or flywheel
install the crankshaft bolt.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-4-1
6G7 ENGINE (E-W) - Air Intake Plenum
4. AIR INTAKE PLENUM
REMOVAL AND INSTALLATION
11 Nm
9
10
11
17 Nm
4 Nm
17 Nm
17 Nm
2
3
21 Nm
4
1
5
12
35 Nm
11 Nm
13
7
6
8
17 Nm
56 Nm
7EN1031
Removal steps
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. Accelerator cable bracket
4. EGR valve
8. Connector bracket
9. Vacuum pipe
10. Throttle body
"AA 11. Throttle body gasket
12. Air intake plenum
5. EGR valve gasket
6. EGR pipe
13. Air intake plenum gasket
7. EGR pipe gasket
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-4-2
6G7 ENGINE (E-W) - Air Intake Plenum
INSTALLATION SERVICE POINTS
"AA THROTTLE BODY GASKET
Protrusion
(1) Install gasket with protrusion as illustrated.
6AE0277
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Dec. 1996
PWEE9615
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11A-5-1
6G7 ENGINE (E-W) - Ignition System
5. IGNITION SYSTEM
REMOVAL AND INSTALLATION
23 Nm
1
3
4
25 Nm
1
2
7EN0965
Removal steps
1. Spark plug cable
2. Spark plug
3. Distributor
4. O-ring
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Timing Belt
11A-6-1
6. TIMING BELT
REMOVAL AND INSTALLATION
23 Nm
21
22
20
13 Nm
19
88 Nm
7
6
23 Nm
10
9
14
12
13
44 Nm
11
17
44 Nm
16
18
8
1
15
48 Nm
2
5
11 Nm
13 Nm
9 Nm
11 Nm
3
7EN0862
44 Nm
4
Removal steps
1. Timing belt front upper cover, rear
2. Timing belt front upper cover, front
3. Timing belt front lower cover
"DA 4. Engine support bracket
5. Crank angle sensor
12. Idler pulley adjusting bracket
13. Adjusting bolt
14. Adjusting stud
15. Crankshaft sprocket
16. Sensing blade
AA" "CA 6. Timing belt
17. Crankshaft spacer
18. Crankshaft key
"BA 7. Automatic tensioner
8. Tensioner pulley
9. Tensioner arm
10. Shaft
AB" "AA 19. Camshaft sprocket bolt
20. Camshaft sprocket
21. Bracket
11. Idler pulley
22. Timing belt rear cover
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-6-2
6G7 ENGINE (E-W) - Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT
(1) When the timing belt is to be reused, in order to allow
re-installation of the belt so that it travels in the same
direction as before it was removed, mark the direction
of travel with an arrow before removing it.
Caution
D
As water or oil on the belt can seriously reduce
its usable life, ensure that the timing belt, sprocket,
and tensioner stay clean and dry while removed,
and never wash them. Parts that have become
too dirty should be replaced.
Whenany oftheparts are oily, checktoseewhether
there are any oil leaks in any of the oil seals or
the camshaft oil seal on the front of the engine.
7EN0145
D
MD998715
MB990767
AB" CAMSHAFT SPROCKET BOLT
(1) Using the Special Tool, hold the camshaft sprocket.
(2) Remove the camshaft sprocket bolt.
7EN0005
INSPECTION
TIMING BELT
Check the belt in detail. If the following is evident, replace
the belt.
(1) Hardened back surface rubber.
Back surface glossy, non-elastic and so hard that even
if a finger nail is forced into it, no mark is produced.
8EN0066
(2) Cracked back surface rubber.
(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
Cracks
(5) Cracked side of belt.
Peeling
Cracks
Cracks
1EN0249
(6) Side of belt badly worn.
NOTE
Rounded edge
Normal belt should have clear-cut sides as if cut with
a sharp knife.
Abnormal wear
(Fluffy strand)
8EN0067
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Timing Belt
11A-6-3
(7) Badly worn teeth.
Initial stage:
Rubber exposed
Canvas is worn (fluffy canvas fibres are visible, rubber
is gone and colour has changed to white. Canvas texture
Tooth missing
and canvas fiber
exposed
is not clear).
Last stage:
Canvas is worn out and rubber exposed and its width
is reduced.
(8) Missing tooth.
8EN0068
AUTO-TENSIONER
(1) Check for oil leaks. If oil leaks are evident, replace the
auto-tensioner.
“L”
(2) Check the rod end for wear or damage and replace the
auto-tensioner if necessary.
(3) Measure the rod projection length “L”. If the reading is
outside the standard value, replace the auto-tensioner.
Standard value “L”: 12 mm
6AE0046
(4) Press the rod by a force of 98 to 196 N and measure
the rod stroke. If the measured value exceeds the standard
value, replace the tensioner.
98 - 196 N
Stroke
Standard value “L”: 1 mm or less
6EN1033
INSTALLATION SERVICE POINTS
"AA CAMSHAFT SPROCKET BOLT
MD998715
(1) Using the Special Tool, hold the camshaft sprocket.
(2) Torque the camshaft sprocket bolt to the specified torque.
MB990767
7EN0005
"BA AUTO-TENSIONER
(1) If the auto-tensioner rod is fully extended, set it in the
retracted position by the following procedure.
1
Set the auto-tensioner in a vice, making sure it is
not tilted.
7EN0225
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
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11A-6-4
6G7 ENGINE (E-W) - Timing Belt
2
Slowly close the vice to force the rod in until the set
A
hole (A) of the rod is lined up with the set hole (B)
of the cylinder.
B
3
4
Insert a metal wire (1.4 mm in diameter) into the set
holes.
Remove the auto-tensioner from the vice.
(2) Install the auto tensioner on the cylinder block through
the oil pump case.
7EN0227
7EN0741
7EN0742
7EN0740
7EN0743
"CA TIMING BELT
(1) Turn the crankshaft sprocket to position its timing mark
3 teeth away from the timing mark on the crankcase. (That
is, slightly lower the No. 1 piston from the top dead centre
on the compression stroke.)
Timing mark
Caution
D
If the camshaft sprocket is turned with the piston
at the top dead centre on the compression stroke,
valves may interfere with the piston.
Crankshaft sprocket
(2) Align the timing marks for the left bank camshaft sprocket.
(3) Align the timing marks for the right bank camshaft sprocket.
Timing mark
Right bank
Left bank
Caution
D
The camshaft sprocket may turn un-intentionally
due to the valve spring tension. Take care not
to injure your fingers.
Crankshaft sprocket
Timing mark
(4) Align timing marks for the crankshaft sprocket.
(5) Install the timing belt over the sprockets in the following
sequence.
1
Place the timing belt over the crankshaft. While
applying tension to the belt, set it over the idler pulley.
Place the belt over the left bank camshaft sprocket.
While applying tension to the belt, place it over the
water pump pulley.
Place the belt over the right bank camshaft sprocket.
Place the belt over the tensioner pulley.
2
3
4
5
Crankshaft sprocket
(6) While pressing the tensioner pulley lightly against the
timing belt, temporarily tighten its centre bolt.
(7) Check that all timing marks are in alignment.
Tensioner pulley
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Timing Belt
11A-6-5
(8) Using the Special Tool, turn the crankshaft counter-
clockwise a quarter turn, then turn it clockwise and align
the timing marks. Make sure that all timing marks are
in alignment.
MD998769
7EN0744
Right bank
Left bank
Timing mark
Water pump
pulley
Camshaft sprocket
Camshaft sprocket
Idler pulley
Tensioner pulley
Auto-tensioner
Crankshaft sprocket
Timing mark
7EN0745
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-6-6
6G7 ENGINE (E-W) - Timing Belt
(9) Set the Special Tool and a torque wrench on the tensioner
pulley.
MB998767
(10)Torque the tensioner pulley to 4.4 Nm.
(11)While holding the tensioner pulley, tighten its centre bolt
to the specified torque.
(12)Turn the crankshaft 2 turns clockwise and let it stand
for approx. 5 minutes.
(13)Remove the wire, which was inserted when installing the
tensioner, from the auto tensioner. If it can be removed
easily, the timing belt tension is correct. Make sure that
the auto tensioner rod projection is within specification.
7EN0746
7EN0747
7EN0873
Standard value: 3.8 - 5.0 mm
(14)If the wire cannot be removed easily or the rod protrusion
is not to specification, repeat steps 9 through 12 to obtain
the correct tension.
"DA ENGINE SUPPORT BRACKET
(1) Tighten bolts to specified torque in the sequence shown.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Intake Manifold
11A-7-1
7. INTAKE MANIFOLD
REMOVAL AND INSTALLATION
17
1
11 Nm
18 Nm
2
19
20
9 Nm
4
18 Nm
5
23
18 Nm
24
26
12
21
22
18
11
10
25
18 Nm
8
9
7
11 Nm
29 Nm
15
6
9 Nm
3
27
16
13 Nm
21 Nm
13
18 Nm
14
28
29
14
31
30
7EN0874
Removal steps
1. Engine harness
"DA 16. Engine coolant temperature sensor
17. Water hose
2. Injector and delivery pipe
3. Insulator
18. Water hose
"HA 4. Fuel pressure regulator
5. O-ring
"CA 19. Heater inlet pipe
"AA 20. O-ring
"CA 21. Heater inlet pipe
"AA 22. O-ring
6. Insulator
"GA 7. Injector
8. O-ring
23. Water outlet fitting
24. Water outlet fitting gasket
25. Water inlet fitting
"BA 26. Thermostat
27. Thermostat housing
28. Thermostat housing gasket
"AA 29. O-ring
9. Grommet
10. Fuel pipe
11. O-ring
12. Delivery pipe
"FA 13. Intake manifold
14. Intake manifold gasket
"EA 15. Engine coolant temperature gauge
30. Water pipe
"AA 31. O-ring
unit
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-7-2
6G7 ENGINE (E-W) - Intake Manifold
INSTALLATION SERVICE POINTS
O-ring
"AA O-RING / WATER PIPE
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
Water pump
D
Keep the O-ring of oil or grease.
Water inlet pipe
Jiggle valve
6EN0594
7EN0876
7EN0877
9EN0091
1EN0338
"BA THERMOSTAT
(1) Install the thermostat in the thermostat case with its jiggle
valve located at the top position.
"CA HEATER INLET AND OUTLET PIPES
Outlet pipe
(1) Attach the outlet and inlet pipes in this order, one on the
top of the other.
Inlet pipe
Surge tank stay
"DA APPLICATION OF SEALANT TO ENGINE
COOLANT TEMPERATURE SENSOR
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
"EA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
Sealant
Specified sealant:
3M ATD Part No. 8660 or equivalent
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Intake Manifold
11A-7-3
"FA INTAKE MANIFOLD
(1) Tighten the nuts on the right bank to 5 - 8 Nm.
Front
(2) Tighten the nuts on the left bank to the specified torque.
Then tighten the nuts on right bank to the specified torque.
(3) Tighten the nuts on the left bank and those on the right
bank again in that order.
7IN0090
7FU0611
6AE0062
"GAINJECTOR
(1) Apply a small amount of engine oil to the O-ring.
Caution
D
Take care to prevent the engine oil from entering
the delivery pipe.
(2) Install the injector into the delivery pipe and turn it right
and left.
(3) Make sure the injector turns smoothly. If not, the O-ring
may be caught. Remove the injector and check for damage
to the O-ring, then re-insert it and confirm that it turns
smoothly.
(4) When installing the injector, set the delivery pipe setting
mark and the injector projecting portion.
Setting
mark
Projection portion
"HA FUEL PRESSURE REGULATOR
(1) Apply a small amount of new engine oil to the O-ring,
then insert the fuel pressure regulator into the delivery
pipe, taking care not to damage the O-ring.
Caution
D
Take care to prevent engine oil from entering the
delivery pipe.
(2) Make sure the regulator turns smoothly. If not, the O-ring
may be caught. Remove the regulator and check for
damage to the O-ring, then re-insert it into the delivery
pipe and confirm that it turns smoothly.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Exhaust Manifold & Water Pump
11A-8-1
8. EXHAUST MANIFOLD & WATER PUMP
REMOVAL AND INSTALLATION
13 Nm
1
3
2
5
13 Nm
35 Nm
4
49 Nm
7
9
41 Nm
6
8
23 Nm
49 Nm
7EN0966
Removal steps
1. Heat protector, rear
6. Exhaust manifold, front
2. Exhaust manifold, rear
"BA 7. Exhaust manifold gasket, front
"AA 8. Water pump
"BA 3. Exhaust manifold gasket, rear
4. Heat protector, front
9. Water pump gasket
5. Engine lift bracket
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-8-2
6G7 ENGINE (E-W) - Exhaust Manifold & Water Pump
INSTALLATION SERVICE POINTS
O-ring
"AA O-RING / WATER PIPE
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
Water pump
D
Keep the O-ring free of oil grease.
Water inlet pipe
6EN0594
"BA EXHAUST MANIFOLD GASKET
(1) Install gaskets with number 1, 3 and 5 embossed on their
top side to the right bank (exhaust manifold (B) side) and
install those with number2, 4and 6to the left bank (exhaust
manifold (A) side).
Cylinder No.
For right bank
1
3
5
Front
(2) Torque the nuts to 30 Nm.
71N0010
Front
For left bank
Cylinder No.
7EN0593
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Rocker Arms and Camshaft
11A-9-1
9. ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
1
3.4 Nm
31 Nm
6
2
10
9
8
3
9
7
5
8
13
9
8
7
12
12 Nm
11
7
12
12
14
15
16
17
Apply engine oil to all
moving parts before
installation.
4
7EN0879
Removal steps
1. Rocker cover
2. Gasket
"CA 10. Rocker arm shaft
"BA 11. Lash adjuster
12. Rocker arm “C”
3. Oil seal
"EA 4. Oil seal
"CA 13. Rocker arm shaft
"BA 14. Lash adjuster
15. Thrust case (left bank)
16. O-ring (left bank)
AA"
AA"
5. Rocker arms, Rocker arm shaft
6. Rocker arms, Rocker arm shaft
"DA 7. Rocker shaft spring
8. Rocker arm “A”
9. Rocker arm “B”
"AA 17. Camshaft
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-9-2
6G7 ENGINE (E-W) - Rocker Arms and Camshaft
REMOVAL SERVICE POINTS
MD998443
AA" LASH ADJUSTER
(1) Before removing the rocker arms and rocker arm shafts,
install the Special Tools to prevent the lash adjusters from
falling off.
6AE0160
9EN0058
7EN0721
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard value:
IN: 37.71 mm
EX: 37.14 mm
Limit:
IN: 37.21 mm
EX: 36.64 mm
LASH ADJUSTER LEAK DOWN TEST
Caution
D
The lash adjuster is a precision part. Keep it free from
dust and other foreign matters.
Do not disassemble lash adjuster.
When cleaning lash adjuster, use clean diesel fuel
only.
D
Diesel fuel
(1) Immerse the lash adjuster in clean diesel fuel.
(2) While lightly pushing down innersteel ballusing theSpecial
Tool (Air bleed wire MD998442), move the plunger up
and down four or five times to bleed air.
Use of the Special Tool (Retainer MD998441) helps
facilitate the air bleeding of the rocker arm mounted type
lash adjuster.
(3) Remove the Special Tool (Air bleed wire MD998442) and
press the plunger. If the plunger is hard to be pushed
in, the lash adjuster is normal. If the plunger can be pushed
in all the way readily, bleed the lash adjuster again and
test again if the plunger is still loose, replace the lash
adjuster.
Caution
D
Uponcompletion ofair bleeding, hold lash adjuster
upright to prevent inside diesel fuel from spilling.
MD998440
(4) After air bleeding, set lash adjuster on the Special Tool
(Leak down tester MD998440).
(5) After plunger has gone down between 0.20 to 0.50 mm,
measure time taken for it to go down a further 1 mm.
Replace if measured time is out of specification.
Graduation
(1 mm)
Standard value: 4 - 20 seconds/1 mm
<Diesel fuel at 15 - 20_C>
Lash adjuster
8EN0059
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Rocker Arms and Camshaft
11A-9-3
INSTALLATION SERVICE POINTS
"AA CAMSHAFT
(1) Before attaching the camshafts, apply engine oil to the
journals and cams.
Take care not to confuse the right bank and left bank
camshafts.
NOTE
The right bank camshaft has 4-mm-wide slits in the rear
end surface.
Slot
7EN0708
(2) Make sure the camshaft dowel pin is at the location shown.
Right bank
Approx
60_
Left bank
Approx
71_
7EN0709
"BA LASH ADJUSTER
(1) Immerse the lash adjuster in clean diesel fuel No. 2.
(2) While pushing down the inside steel ball with the special
air bleeding wire tool, move the plunger up and down
four or five times to evacuate air from the lash adjuster.
MD998442
7EN0721
7EN0722
9EN0511
(3) Taking care not to spill the diesel fuel, install the lash
adjuster into the rocker arm and attach a special tool to
prevent it from falling out.
MD998443
Lash adjuster
"CA ROCKER ARM SHAFT
Timing belt side
(1) The end with the larger chamfer is at the right on the
front bank and at the left on the rear bank.
NOTE
Chamfered
The side with the four bolt holes is on the intake side.
(2) The side with the oil holes is on the lower side (cylinder
head side).
Oil hole
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-9-4
6G7 ENGINE (E-W) - Rocker Arms and Camshaft
"DA ROCKER SHAFT SPRING
Rocker shaft
spring
(1) Insert the rocker shaft spring at a slant with respect to
the spark plug guide and install it normal to the guide.
7EN0723
6AE0164
7EN0724
"EA OIL SEAL
MD998713
Left bank side
MB991559
MD998713
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Cylinder Head and Valves
11A-10-1
10. CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
108 Nm
1
Apply engine oil to all
moving parts before
installation.
2
5
7
6
13
14
11
16
17
3
9
10
22
15
18
21
12
19
20
8
4
7EN0915
Removal steps
AA"
1. Cylinder head bolt
2. Washer
12. Exhaust valve
AC" "AA 13. Valve stem seal
3. Cylinder head assembly
4. Cylinder head gasket
14. Valve spring seat
AC" "AA 15. Valve stem seal
16. Valve spring seat
AB" "CA 5. Retainer lock
6. Valve spring retainer
"BA 7. Valve spring
8. Intake valve
17. Intake valve guide
18. Snap ring
19. Exhaust valve guide
20. Intake valve seat
21. Exhaust valve seat
22. Cylinder head
AB" "CA 9. Retainer lock
10. Valve spring retainer
"BA 11. Valve spring
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-10-2
6G7 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL SERVICE POINTS
AA" CYLINDER HEAD BOLT
MD998051
6AE0166
AB" RETAINER LOCK
MD998735
(1) Attach a tag with the cylinder No. and mounting location
to the detached valves, springs and other parts and store
them for reassembly.
7EN0892
MD998772
6AE0167
AC" VALVE STEM SEAL
Caution
D
Do not reuse the stem seal.
7EN0444
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Cylinder Head and Valves
11A-10-3
INSPECTION
CYLINDER HEAD
(1) Checkthecylinderhead forwater leaks, gas leaks, damage
or cracks before washing it.
(2) Completely remove oil, fur, sealer, carbon and the like.
After washing the oil passages, blow air through them
to make sure they are not clogged.
(3) To ensure flatness of the cylinder head bottom surface,
measure the distortion of the surface using a straight edge
and a thickness gauge. When the distortion exceeds the
specifications, correct by grinding the surface.
7EN0258
Standard values of bottom surface distortion:
Within 0.03 mm
Limit: 0.2 mm
Grinding limit: 0.2 mm
Height of the cylinder head: 120 mm
Caution
D
The cylinder head bottom surface may be ground
to within 0.2 mm of the mating cylinder block.
VALVES
(1) When contact between the valve and the valve seat is
improper, unbalanced or nonexistent, correct the valve
seat.
Contact to be at
the centre of the
valve face.
(2) Change the valve when the margin doesn’t meet the
specifications.
Margin
Standard value:
Intake 1.0 mm
Exhaust 1.2 mm
Intake 0.5 mm
Exhaust 0.7 mm
Limit:
6EN0542
(3) Measure the total length of the valve. If the measured
value is below the limit, change the valve.
Standard value:
Intake 112.30 mm
Exhaust 114.11 mm
Intake 111.80 mm
Exhaust 113.61 mm
Limit:
VALVE SPRING
(1) Measure the free height of the valve spring. When the
measured value exceeds the specified limit, change the
valve spring.
2_
Standard value: 51.0 mm
Limit: 50.0 mm
(2) Measure the perpendicularity of the valve spring. When
the measured value exceeds the specified limit, change
the valve spring.
Free height
Standard value: 2_ max.
Limit: 4_
1EN0264
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-10-4
6G7 ENGINE (E-W) - Cylinder Head and Valves
VALVE GUIDE
(1) Measure the clearance between the valve guide and the
Stem outside diameter
valve stem. When the clearance exceeds the specified
limit, change the valve guide or the valve or both.
Standard value:
Intake 0.02 - 0.04 mm
Exhaust 0.04 - 0.06 mm
Limit:
Intake 0.10 mm
Exhaust 0.15 mm
Guide inside diameter
1EN0279
VALVE SEAT
Valve stem
end
(1) Assemble the valve, and with it pressed down on the
valve seat measure the part of the valve which protrudes
from the spring seat surface. The length measured should
be between the spring seat surface and the valve stem
end. If the measured value exceeds the limit, change the
valve.
Valve
protrusion
Spring seat
surface
Standard value: 49.3 mm
Limit: 49.8 mm
DEN0212
VALVE SEAT RECONDITIONING PROCEDURE
(1) Check the clearance between the valve guide and the
valve, and if necessary, change the valve guide before
correcting the valve seat.
65_
65_
(2) Correct so that the valve seat width and angle are as
specified in the figure at left.
25_
(3) After making the corrections, apply lapping compound
and adjust the valve and valve seat.
44_
15_
44_
7EN0273
VALVE SEAT REPLACEMENT PROCEDURE
0.5 - 1 mm
(1) Cut off the inside of the valve seat to reduce its thickness
before pulling out the valve seat.
(2) Adjust the valve cylinder hole in the cylinder head to the
diameter of the oversize valve seat to be press fitted.
Cut off
Intake valve seat hole diameter
0.30 O.S.
0.60 O.S.
34.30 - 34.33 mm
34.60 - 34.63 mm
0.5 - 1 mm
Exhaust valve seat hole diameter
1EN0274
0.30 O.S.
0.60 O.S.
31.80 - 31.83 mm
32.10 - 32.13 mm
(3) When press fitting a valve seat, cool it using liquid nitrogen
so as not to gall the cylinder head inside diameter.
(4) Machine the valve seat.
(5) See “Valve seat reconditioning procedure.”
Height of
valve seat
Oversize hole diameter
1EN0275
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Cylinder Head and Valves
11A-10-5
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Remove the snap ring from the exhaust valve guide.
(2) Pull out to the cylinder block side using a press.
(3) Machine the valve guide hole in the cylinder head to match
the oversize valve guide to be press fitted.
Caution
D
Do not press fit another valve guide of the same
size.
14.0 mm
Diameter of the valve guide hole
7EN0726
0.05 O.S.
0.25 O.S.
0.50 O.S.
11.05 - 11.07 mm
11.25 - 11.27 mm
11.50 - 11.52 mm
(4) Press fit the valve guide until the projection is 14.0 mm,
as shown.
NOTE
D
Press fit the valve guide from the top surface of the
cylinder head.
D
Pay attention to the difference in the valve guide length
(45.5 mm for the intake side valve guide and 50.5
mm for the exhaust side valve guide).
After press fitting the valve guide, insert a new valve
and check the contact between the valve guide and
the valve.
D
INSTALLATION SERVICE POINTS
I.D. Colour
Black
"AA VALVE STEM SEAL
I.D. Colour
Silver or white
(1) Attach a valve spring seat.
(2) Attach a new stem seal to the valve guide with the Special
Tool.
NOTE
Pay attention to the difference between the intake side
and exhaust side valve stem seals.
Intake side
Exhaust side
Identifying colour at the valve stem seal portion
Intake side: Silver or white
7EN0763
Exhaust side: Black
MD998774
Caution
D
Do not reuse valve stem seals.
D
Always use the Special Tool to install valve stem
seals. Improper installation will cause oil leaks.
6AE0169
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-10-6
6G7 ENGINE (E-W) - Cylinder Head and Valves
"BA VALVE SPRING
Spring
retainer
Identification
colour
(1) Install the valve spring painted red side up.
Stem seal
Spring seal
6EN0544
"CA VALVE RETAINER LOCK
MD998735
(1) Using Special Tool install the valve retainer lock.
7EN0892
MD998772
6AE0167
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Oil Pan and Oil Pump
11A-11-1
11. OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
20
21
22
18
13
13 Nm
9.8 Nm
9.8 Nm
19
16
12
3
18 Nm
11
41 Nm
17
15
44 Nm
14
4
1
11 Nm
9.8 Nm
10
9.8 Nm
23 Nm
9
8
23 Nm
11 Nm
7
2
39 Nm
5
5.9 Nm
6
11 Nm
7EN0893
Removal steps
"GA 1. Oil pressure switch
"FA 2. Oil filter
12. Oil screen gasket
13. Baffle plate
14. Plug
3. Oil filter bracket
4. Oil filter bracket gasket
5. Drain plug
15. Relief spring
16. Relief plunger
6. Drain plug gasket
AA" "EA 7. Oil pan, lower
8. Cover
"CA 17. Oil seal
"BA 18. Oil pump case
19. O-ring
AB" "DA 9. Oil pan, upper
10. Baffle plate
20. Oil pump cover
AC" "AA 21. Oil pump outer rotor
11. Oil screen
AC" "AA 22. Oil pump inner rotor
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-11-2
6G7 ENGINE (E-W) - Oil Pan and Oil Pump
REMOVAL SERVICE POINTS
AA" OIL PAN (LOWER)
(1) Apply wood to the oil pan side and remove the oil pan
lower with a plastic hammer.
AB" OIL PAN (UPPER)
(1) Detach the bolt (1) shown at left.
(2) Detach all other bolts.
1
7EN0564
(3) Screw a bolt into bolt hole A shown (at both ends) to
remove the oil pan.
Caution
D
Do not use a scraper or special tool to remove
the oil pan.
A
7EN0565
7EN0509
7EN0510
AC" OIL PUMP OUTER AND INNER ROTORS
Alignment marks
(1) Draw a setting mark on the oil pump outer and inner rotors
to facilitate reassembly.
INSPECTION
OIL PUMP
(1) Check for tip clearance.
Standard value: 0.06 - 0.18 mm
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Oil Pan and Oil Pump
11A-11-3
(2) Check for side clearance.
Standard value: 0.04 - 0.10 mm
7EN0511
(3) Check for body clearance.
Standard value: 0.10 - 0.18 mm
Limit: 0.35 mm
7EN0512
INSTALLATION SERVICE POINTS
Alignment marks
"AA OIL PUMP INNER AND OUTER ROTORS
(1) Install the oil pump outer rotor in the proper direction using
the setting mark drawn on it before disassembly.
Apply engine oil over the entire rotor surface.
7EN0509
"BA OIL PUMP CASE
(1) Remove the old liquid gasket from the cylinder block (oil
pump mounting surface) and from the oil pump.
(2) Squeeze out about 3 mm of liquid gasket (FIPG) and
coat the coating surface with it.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 or
equivalent
7EN0767
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-11-4
6G7 ENGINE (E-W) - Oil Pan and Oil Pump
"CA OIL SEAL
Oil pump case
MD998717
7EN0139
MD998717
Crankshaft
Guide
Oil seal
7EN0468
"DA OIL PAN (UPPER)
(1) Clean the gasket coating surfaces of the cylinder block
and the oil pan upper.
(2) Squeeze out a 4 mm bead of liquid gasket and coat the
coating surface with it.
NOTE
A
During attachment of the oil pan upper, the sealer must
not be expelled from the flange portion of the oil pan
for distance A as shown.
Top view
Flange bolt tightening sequence
Liquid gasket:
11
MITSUBISHI GENUINE Part No. MD970389 or
equivalent
9
4
1
5
8
14
15
18
2
6
16
17
13
3
7
10
12
Bottom view
7EN0568
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Oil Pan and Oil Pump
11A-11-5
"EA OIL PAN (LOWER)
(1) Clean the gasket coating surfaces of the oil pan upper
and the oil pan lower.
(2) Squeeze out a 4 mm bead of liquid gasket and coat the
coating surface with it.
Liquid gasket:
MITSUBISHI GENUINE Part No. MD970389 or
equivalent
View from above
lower oil pan
Flange bolt tightening sequence
4
6
2
10
9
7
8
5
3
1
View from the bottom of the lower oil pan
7EN0894
"FA OIL FILTER
(1) Clean the oil filter attaching surface on the side of the
cylinder block.
(2) Apply engine oil to the O-ring for the oil filter.
(3) Screw in the oil filter and from the point at which the
O-ring contacts the oil filter attaching surface, tighten it
by about one turn (at approx. 14 Nm).
Bracket side
Engine oil
6EN0591
"GAOIL PRESSURE SWITCH
Sealer: 3M ATD Part No. 8660 or equivalent
NOTE
D
D
Sealer must not extend beyond the tip of the thread portion.
Take care not to tighten the switch too much.
9EN0094
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Piston and Connecting Rod
11A-12-1
12. PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
8
6
10
4
7
9
11
12
5
3
2
51 Nm
1
7EN0424
Removal steps
1. Connecting rod cap nut
"CA 7. Piston ring No. 2
AA" "EA 2. Connecting rod cap
"BA 8. Oil ring
3. Connecting rod bearing, lower
AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod assem-
bly
10. Piston
11. Connecting rod
5. Connecting rod bearing, upper
"CA 6. Piston ring No. 1
12. Connecting rod cap bolt
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-12-2
6G7 ENGINE (E-W) - Piston and Connecting Rod
REMOVAL SERVICE POINTS
AA" CONNECTING ROD CAP
(1) Enter the cylinder No. on the side of the large end of
the connecting rod to facilitate reassembly.
Cylinder No.
7EN0448
AB" PISTON PIN
Guide B
The special piston pin setting tool (MD998780) consists of
the parts shown at left.
Push rod
Guide A:
17.9 mm
Guide A:
18.9 mm
Guide C
Guide A:
20.9 mm
Base
Guide A:
21.9 mm
7EN0431
(1) Insert the special push rod tool from the front marked
(arrow) side of the piston side and attach guide C.
(2) Set the piston and connecting rod assembly to the special
tool piston pin setting base such that the front mark on
the piston faces upward.
Push rod
(3) Pull out the piston pin with a press.
NOTE
Front mark
Front
mark
After pulling out the piston pin, place the piston, the piston
pin, and the connecting rod in order for each cylinder
number.
Guide C
Base
7EN0390
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Piston and Connecting Rod
11A-12-3
INSPECTION
PISTON RING
(1) Check the clearance between the piston ring and the ring
groove. If it exceeds the specified limit, change the ring
or the piston and piston ring.
Standard values: No. 1 0.03 - 0.07 mm
No. 2 0.02 - 0.06 mm
Limit:
0.1 mm
7EN0475
(2) Place the piston ring in the cylinder bore, push it in by
applying the piston head side, and make sure it is square.
Then measure the clearance at the ring ends with a
thickness gauge.
Push in using
the piston
Change the piston ring if the clearance at the ring end
is excessive.
Standard values: No. 1 0.30 - 0.45 mm
No. 2 0.45 - 0.60 mm
Oil
0.20 - 0.60 mm
End clearance
Limit:
No. 1 0.8 mm
No. 2 0.8 mm
Piston ring
7EN0476
Oil
1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAUGE
METHOD)
(1) Drain oil from the crankshaft pin and the connecting rod
bearing.
(2) Place a piece of Plastigauge the length of the bearing
width on the crankshaft pin straight along the pin centre.
(3) Gently place the connecting rod cap on top and tighten
the bolt to the specified torque.
(4) Detach the bolt and gently remove the connecting rod
cap.
(5) MeasurethewidthofthecrushedPlastigauge(atthewidest
point) using the scale printed on the Plastigauge package.
1EN0246
Standard value: 0.02 - 0.05 mm
Limit: 0.1 mm
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-12-4
6G7 ENGINE (E-W) - Piston and Connecting Rod
INSTALLATION SERVICE POINTS
"AA PISTON PIN
(1) Measurethedimensionsofthefollowingpartsandportions:
A: Piston pin mounting portion
B: Distance between piston bosses
C: Piston pin
C
D
D: Connecting rod
Connecting rod
(2) Calculate by substituting each measured value into the
following equation:
Piston pin
Piston
(A - C) - (B - D)
L =
2
(3) Insert the special push rod tool into the piston pin and
attach guide A to it.
(4) Combine the piston and the connecting rod, matching
their front marks.
A
B
(5) Apply engine oil to the outer periphery of the piston pin.
(6) Insert the side of the piston pin guide A attached per
Step (3) into the pin hole from the side of the piston
containing the front mark.
7EN0432
(7) Screw guide B into guide A until they are distance L
(obtained per Step (2) above) plus 3 mm apart as shown.
(8) Use special tools to set the piston pin to a special tool
piston setting base with the front mark of the piston facing
up.
3 mm + L
(9) Press fit the piston pin with a press. When the load required
for press fitting the piston pin is below the standard value,
change the piston pin (piston assembly) or the connecting
rod or both.
Standard values: 7,350 - 17,200 N
Guide B
Guide A
7EN0433
Push rod
Piston pin
Front mark
Guide A
Front
mark
Base
Guide B
7EN0391
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Piston and Connecting Rod
11A-12-5
"BA OIL RING
(1) Install the oil ring spacer into the piston ring groove. Next
install the upper side rail into the piston ring groove, and
then install the lower side rail.
NOTE
D
There is no distinction between the upper and lower
surfaces of the side rail and spacer.
D
The spacer and side rail (new part) are painted the
following colour to enable size identification.
Side rail
S.T.D.
Identification colour
None
Blue
Side rail end
0.50 mm O.S.
1.00 mm O.S.
Yellow
(2) The side rail can be inserted easily into the piston groove
by first inserting one end and then pushing the rail into
place while turning it by hand as shown.
Caution
D
The side rail may break if a ring expander is used.
7EN0451
(3) After installation into the piston, make sure the side rail
turns smoothly in either direction.
"CA PISTON RING NO. 2 / PISTON RING NO. 1
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
D
Note the difference in shape between No. 1 and No.
2 piston rings.
Piston ring expander
D
Install piston rings No. 1 and No. 2 with their side
having marks facing up (on the piston crown side).
7EN0452
Identification mark
Identification mark
Size mark
9EN0524
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-12-6
6G7 ENGINE (E-W) - Piston and Connecting Rod
"DA PISTON AND CONNECTING ROD
No. 1
Upper side rail
(1) Liberally coat the circumference of the piston, piston ring,
and oil ring with engine oil.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
Piston pin
(3) Rotate the crankshaft so that the crank pin is positioned
at the centre line of the cylinder bore.
(4) Use suitable thread protectors on connecting rod bolts
before inserting piston and connecting rod assembly into
cylinder block.
Care must be taken not to nick crank pin.
(5) Using a suitable piston ring compressor tool, install piston
and connecting rod assembly into cylinder block.
Lower side rail
No. 2 ring gap
and spacer gap
6EN0549
Caution
D
Install the piston with the front mark (arrow mark)
on the top of the piston facing towards the engine
front (timing belt side).
7EN0032
"EA CONNECTING ROD CAP
(1) Mate the correct bearing cap with the correct connecting
rod by checking with the alignment marks marked during
disassembly. If a new connecting rod is used which has
no alignment mark, position the notches for locking the
bearing on the same side.
Cylinder
number
Notches
7EN0453
(2) Check if the thrust clearance in the connecting rod big
end is correct.
Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm
7EN0454
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate 11A-13-1
13. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE
REMOVAL AND INSTALLATION
1
2
Apply engine oil to all
moving parts before
installation.
6
8
74 Nm
11 Nm
11 Nm
7
74 Nm
3
4
5
18
16
15
17
14
12
11
13
10
9
93 Nm
7EN1032
Removal steps
1. Adaptor plate
2. Drive plate
"BA 10. Bearing cap
"AA 11. Thrust bearing (A)
"AA 12. Thrust bearing (B)
3. Plate
4. Adaptor plate
5. Flywheel
"AA 13. Crankshaft bearing (lower)
14. Crankshaft
6. Rear plate
"AA 15. Thrust bearing (B)
16. Thrust bearing (A)
"DA 7. Oil seal case
"CA 8. Oil seal
17. Crankshaft bearing (upper)
18. Cylinder block
"BA 9. Bearing cap bolt
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-13-2 6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
INSPECTION
Plastigauge
CRANKSHAFT OIL CLEARANCE (PLASTIGAUGE
METHOD)
NOTE
If the oil clearance exceeds the limit, replace the bearing,
and crankshaft if necessary.
This crankshaft oil clearance can be measured easily by using
a plastic gauge, as follows:
7EN0459
1
Remove oil and grease and any other foreign material
from crankshaft journal and bearing inner surface.
Install the crankshaft.
Cut the plastigauge to the same length as the width of
bearing and place it on journal in parallel with its axis.
Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
Remove the bolts and gently remove the crankshaft
bearing cap.
2
3
4
5
6
Measure the width of the crushed plastic gauge at its
widest section by using a scale printed on the plastigauge
package.
7EN0141
7EN0460
7EN0461
Standard values: 0.02 - 0.04 mm
Limit: 0.1 mm
CYLINDER BLOCK
(1) Visually check for scratches, rust and corrosion. Also use
flaw detecting agents and the like to check for cracks.
If there are any defects, rectify the cylinder block.
(2) Measure the flatness of the cylinder block top surface
with a straight edge and a thickness gauge. During
measurement, the cylinder block top surface must be free
from gasket pieces and the like.
Standard values: 0.05 mm
Limit: 0.1 mm
(3) Check for scratches or seizure of the cylinder wall. If there
are any defects, correct (bore it a oversize) or change
the cylinder block.
(4) Measure the inside diameter and the ovality of the cylinder.
If the cylinder is overly worn, correct it to a larger size
and change the pistons and the piston rings.
12 mm
Standard value:
Cylinder inside diameter 91.1 mm
Ovality: 0.01 mm
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate 11A-13-3
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size
Identification mark
Thrust
direction
0.50 mm O.S.
1.00 mm O.S.
0.50
1.00
Piston O.D.
NOTE
6EN0554
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension = Piston O.D. + (Clearance
between piston O.D. and cylinder) - 0.02 mm (honing
margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
D
To prevent distortion that may result from
temperature rise during honing, bore cylinders,
in the order of No. 1, No. 2, No. 3, No. 4, No. 5
and No. 6.
(5) Hone to the final finish dimension (Piston O.D. + clearance
between piston O.D. and cylinder.)
(6) Check the clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-13-4 6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
INSTALLATION SERVICE POINTS
Identification colour position
"AA CRANKSHAFT BEARING
When bearing replacement is required, select and install the
correct bearing by the following procedure.
(1) Measure the crankshaft journal diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification
colours/marks of its journals are painted/stamped at the
positions shown in the illustration.
No. 4
journal
No. 3
journal
No. 2
journal
No. 1
journal
7EN0991
(2) The cylinder block bearing bore diameter identification
marks are stamped at the position shown in the illustration
from left to right, beginning at No. 1.
Cylinder bore size mark
No. 2
No. 4
No. 1
No. 3
Cylinder block bearing
bore identification mark
Timing belt side
7EN0992
Combination of crankshaft journal diameter and cylinder block bearing bore diameter
Crankshaft journal
Bearing
identification
colour or
Cylinder block
bearing bore
diameter
identification
mark (for service
part)
Classification
Identification colour
Production part Service part
O.D. mm
identification
mark
1
None
None
None
Yellow, 0
None, 1
White, 2
59.994 - 60.000
I
II
III
I
Pink, 1
Red, 2
Green, 3
Red, 2
2
3
59.988 - 59.994
59.982 - 59.988
II
III
I
Green, 3
Black, 4
Green, 3
Black, 4
Brown, 5
II
III
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate 11A-13-5
(3) Select the correct bearing from the above table on the
Identification mark
basis of the identification data confirmed at steps 1 and
2.
Example
D
If the measured value of a crankshaft journal outer
diameter is 59.996 mm, the journal is classified as
“1” in the table.
In case the crankshaft is also replaced by a spare
part, check the identification colours of the journals
painted on the new crankshaft. If the colour is yellow,
for example, the journal is classified as “1”.
Next, check the cylinder block bearing bore
identification mark stamped on the cylinder block. If
it is “1”, read the “Bearing identification colour” column
to find the identification colour of the bearing to be
used. In this case, it is “pink”.
Identification
colour
7EN0600
D
Oil groove
Groove
(4) Install the bearing halves with oil groove on the cylinder
block side.
(5) Install the bearing halves without oil groove on the bearing
cap side.
(6) Install the thrust bearings on both sides of the No. 3 bearing
with the grooves facing outward.
7EN0602
"BA BEARING CAP / BEARING BOLT
(1) Attach the bearing cap on the cylinder block as shown
in the figure.
(2) Tighten the bearing cap bolts to the specified torque in
the sequence shown in the figure.
(3) Check that the crankshaft rotates smoothly.
Bearing cap
Front mark
Bearing cap bolt
8
7
4
1
5
6
3
2
Crankshaft
Cylinder block
7EN0609
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
11A-13-6 6G7 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
(4) Check the end play. If it exceeds the limit value, replace
the thrust bearing.
Standard value: 0.05 - 0.25 mm
Limit: 0.3 mm
7EN0034
7EN0465
7EN0467
"CA CRANKSHAFT REAR OIL SEAL
(1) Using the Special Tool, press-fit a new crankshaft rear
oil seal into the seal case.
MD998718
Oil seal
case
"DA OIL SEAL CASE
(1) Squeeze out a 3 mm bead of liquid gasket (FIPG) and
apply it to the coating surface.
Liquid gasket:
MITSUBISHI GENUINE Part No. MD970389
Mitsubishi Motors Corporation
Dec. 1996
PWEE9615
E
NOTES
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